Pajero Tech Data Base

[bakerboy]

As stolen from Frank off outerlimits, this should help with the weekly, will this gearbox mate up with this engine/ will this diff fit my paj etc

Motor and Gearbox Combos

Gen 1

NA model Jan 83-Nov 84
swb 2.6 petrol & 2.3 TD 5sp (KM145) only
Hi-roof lwb introduced in May 84 with 2.6 petrol & 2.3 TD

NB model Nov 84-Nov 85
same variants as above except 2.3 TD not available with swb

NC model Nov 85-Oct 86
same variants as above except hi-roof lwb is replaced with low-roof version

ND model Oct 86-Oct 87
swb 2.6 petrol 5sp (KM145)
lwb 2.6 petrol & 2.5 TD 5sp (KM145)
Optional non lock up 4sp auto (KM148) for 2.6 petrol

NE model Oct 87-Sept 88
same variants as above
2.6 Jap petrol replaced with improved locally Oz made Astron 2 versions

NF model Sept 88-Sept 89
same variants as above
3.0 V6 introduced for lwb with 5sp (V5MT1) or 4sp auto (KM148)
3 link coil spring rear introduced for lwb 3.0 V6

NG model Sept 89-Apr 91
same variants as above except KM148 replaced with lock up 4sp V4AW2
2.5 TD was intercooled in 1990
rear disc brakes added with 3 link coil spring rear

Gen 2

NH model Apr 91-Nov 93
swb 2.6 petrol 5sp (V5M21) leaf springs 3.0 V6 5sp (V5MT1) rear coils
lwb 2.6 petrol 5sp (V5M21) leaf springs 2.5 TD 5sp (V5M21) leaf springs 2.5 TDI 5sp (V5MT1) rear coils 3.0 V6 5sp (V5MT1) or 4sp auto (V4AW2) rear coils

NJ model Nov 93-Mar 97
rear leaf springs dropped everything now 3 link coils
swb 3.0 V6 5sp (V5MT1) or 4sp auto (V4AW2)
lwb 2.8 D 5sp (V5M21) 2.8 TDI 5sp (V5M31) 3.0 V6 5sp (V5MT1) or 4 sp auto (V4AW2)
Luxury Exceed model 3.5 DOHC V6 lwb 4 sp auto (V4AW3)
Sep 95 3.5 DOHC V6 made standard across range (3.0 V6 dropped)

NK model Mar 97-Oct 97
swb 3.5 DOHC V6 5sp (V5M31) or 4sp auto (V4AW3)
lwb 2.8 TDI 5sp (V5M31) 3.5 DOHC V6 5sp (V5M31) or 4sp auto (V4AW3)

NL model Oct 97-Jul 00 (known as Gen 2.5 in US)
swb same as NK
lwb same as NK except 3.5 DOHC V6 replaced with 3.5 SOHC V6

Gen 3

NM model Jul 00-Oct 02 (monocoque body / IRS)
swb dropped from range
lwb 2.8 TDI 5sp (V5M31) 3.5 SOHC V6 5sp (V5M31) or new 5sp tiptronic auto (V5A51 Invecs 2)
Aug 02 3.2 DID introduced (2.8 TDI dropped)

NP model Oct 02-Oct 06
traction / stability control introduced
lwb 3.5 SOHC V6 5sp (V5M31) or 5sp auto (V5A51) 3.2 DID 5sp (V5M31) or 5sp auto (V5A51)
Oct 03 3.8 SOHC introduced only with 5sp auto (V5A51)
Jan 05 MATT (Mitsu All Terrain Technology) introduced across model range

Gen 4

NS model Oct 06-
new body and interior reintroduction of swb
optional rear difflock
introduction of MIVEC 3.8 SOHC V6
introduction of common rail injection and DPF on 3.2 CDI
transmissions the same as Gen 3

Engine Power Outputs

Gen 1

2.6 Jap (4G54) = 76Kw 192Nm
2.6 Oz (4G54) = 79Kw 196Nm
2.3 TD (4D55T) = 62Kw 188Nm
3.0 V6 (6G72) = 105Kw 228Nm
2.5 TD (4D56T) = 62Kw 201Nm
2.5 TDI (4D56TI) = 70Kw 240Nm

Gen 2

2.6 Oz (4G54) = 79Kw 196Nm
3.0 V6 (6G72) = 109Kw 234Nm
2.5 TDI (4D56TI) = 73Kw 240Nm
2.8 D (4M40) = 71Kw 198Nm
2.8 TDI (4M40) = 92Kw 292Nm
3.5 DOHC V6 (6G74) = 153Kw 300Nm
3.5 SOHC V6 (6G74) 140Kw 303Nm

Gen 3

2.8 TDI (4M40) = 92Kw 292Nm
3.5 SOHC V6 (6G74) = 140Kw 303Nm
3.2 DID (4M41) = 121Kw 373Nm
3.8 SOHC V6 (6G75) = 150Kw 314Nm

Gen 4

3.8 SOHC V6 MIVEC (6G75) = 184Kw 329Nm
3.2 CDI (4M41) = 118Kw 378Nm (auto) 125Kw 358Nm (5sp)
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T/case & Final Drive Ratio's

Gen 1

2.3 TD = 4.875, 5.29
2.6 / 2.5 TD = 4.625, 4.875
2.5 TDI = 4.625, 4.875
3.0 V6 = 4.625, 4.875
t/case = 1.944:1 low range for 2.6, 2.3 TD & 2.5 TD, 1.925:1 for 3.0 V6

Gen 2

2.6 = 4.875
2.5 TD & 2.5 TDI = 4.875, 5.29
3.0 V6 = 4.625, 4.875
2.8 D = 4.875
2.8 TDI = 4.90
3.5 DOHC V6 = 4.636
t/case = 1.925:1 low range for 2.6, 2.5 TD, 2.5 TDI & 3.0 V6, 1.90:1 for 2.8 TDI & 3.5 DOHC V6

Gen 3

2.8 TDI = 4.90 5sp man
3.2 DID = 3.90 5sp auto or 4.10 for 5sp man
3.5 SOHC V6 = 4.30 5sp man & 5sp auto
3.8 SOHC V6 = 4.30 5sp auto
t/case = 1.90:1 for all

Gen 4

3.8 SOHC V6 MIVEC = 4.30 5sp man and 5sp auto
3.2 CDI = 4.10 5sp man or 3.917 for 5sp auto
t/case = same as Gen 3

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Axle Data

Gen 1

2.6, 2.3TD, 2.5TD & 2.5TDI (some) :-
front axle = 25 spline, 29mm diameter, diff = 7.25" diameter (low pinion)
front axle = 28 spline, 29mm diameter, diff = 7.25" diameter (low pinion from an L300)
rear axle = 28 spline, 30.5mm diameter, diff = 8" diameter
3.0V6 :-
front axle = 28 spline, 29mm diameter, diff = 8" diameter (low pinion)
rear axle = 28 spline, 30.5mm diameter, diff = 9" diameter

Gen 2

3.0V6 :-
same as Gen 1 except for NH & NJ auto has 7.25" diameter front diff (high pinion) NH & NJ 5sp man has 8" diameter front diff (high pinion)
2.5TDI :-
same as NH & NJ auto
3.5V6 & 2.8TDI :-
front axle = 28 spline, 29mm diameter, diff = 8" diameter (high pinion)
rear axle = 31 spline, 33.5mm diameter, diff = 9.5" diameter

Gen 3

3.5V6, 2.8TDI, 3.2DID, 3.8V6
front axle = 28 spline, 29mm diameter, diff = 8" diameter (high pinion)
rear axle = 33 spline, 36mm diameter, diff = 9.5" diameter

Gen 4
same as Gen 3

Note :- Mitsu factory Aisin manual hubs (found on some models - Gen 1 or Gen 2 base models & Tritons) are interchangeable and will retrofit to all Gen 2 models with super select.
These will not fit to a Gen 3 model as they run solid one piece hub flanges (non-removable).

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Brake Data

Gen 1

swb
front = NA-ND 255mm vented discs (20mm thick) single piston calipers (53.97mm pistons)
front = NE-NG 258mm vented discs (22mm thick) single piston calipers (57.15mm pistons)
rear = NA-ND 254mm drums (20.64mm wheel cylinder)
rear = NE-NG 254mm drums (22.23mm wheel cylinder)
lwb
front = NA-NE 275mm vented discs (20mm thick) single piston calipers (57.15mm pistons)
front = NF-NG (3.0V6) 276mm vented discs (22mm thick) single piston calipers (42.8mm pistons)
rear = drums NA-ND same as swb, NE-NG same as swb
rear = NF-NG (3.0V6) 315mm solid discs (18mm thick) single piston calipers (42.8mm pistons)

Gen 2

front = NH-NJ (3.0V6) 276mm vented discs (24mm thick) twin piston calipers (42.8mm pistons)
front = NJ-NL (3.5V6) 276mm vented discs (27mm thick) twin piston calipers (42.8mm pistons)
front = NK & NL GLS only 314mm vented discs (24mm thick) twin piston calipers (42.8mm pistons)
rear = NH-NL 315mm solid discs (18mm thick) single piston calipers (42.8mm pistons)
Note :- NH GL base models had rear drum brakes same as Gen 1 NE-NG
Also NK & NL GLS models have to run 16" rims to clear the bigger front rotors.

Gen 3

front = NM-NP 290mm vented discs (26mm thick) twin piston calipers (45.4mm pistons)
rear = NM-NP 300mm vented discs (22mm thick) single piston calipers (44.5mm pistons)

Gen 4

front = NS lwb 280mm vented discs (28mm thick) 4 piston calipers (45.4mm pistons). NS swb 240mm vented discs (26mm thick) twin piston calipers (45.4mm pistons)
rear = NS lwb 285mm vented discs (18mm thick) single piston calipers (48mm pistons). NS swb 280mm vented discs (22mm thick) single piston calipers (44.5mm pistons)

Note: When performing the brake caliper swap from a gen2 to a gen1, take the soft brake lines off the gen2 and use them on the gen 1, they are slightly longer for the lift most people have and are newer then the gen1 lines, hence less cracking etc in the lines

[bakerboy]

Transfer Cases are touch and go depending on super select between the gen1 and 2's

[bakerboy]

Re-edited with new L300 front diff info

[Vicks]

good info. thanks for compiling this.

[Gus]

Well done Bakerboy..(Sticky applied)

Gus.

[Leggator]

Great info. I also found this info on wikipedia:

http://en.wikipedia.org/wiki/Mitsubishi_4M4_engine#4M41

Looks like as of 2010 turbo diesels produce 147kW of power and 441Nm of torque.

Anyone knows how to determine the generation of 4M41 engine? I'm really keen to know whether my 2010 Activ is 1st or 2nd generation.

[bakerboy]

More good info from our fellow forumites, just to note montero is a Pajero, and montero sport is a challenger


TORQUE SPECIFICATIONS

Application Ft. Lbs. (N.m)
Adjusting Bolt Lock Nut .................................... 27 (37)
Idler Arm Bracket-To-Frame Bolt & Nut
Montero ............................................ 40-47 (54-64)
Montero Sport ............................................ 43 (59)
Idler Arm-To-Bracket Lock Nut ............................. 101 (44)
Oil Pump Cover Bolts ....................................... 15 (20)
Pitman Arm-To-Cross Shaft Nut
Montero ........................................ 108-123 (146-176)
Montero Sport .................................. 108-123 (147-167)
Pressure Hose In-Line Fitting
Montero .................................................. 25 (34)
Montero Sport ............................................ 16 (22)
Relay Rod-To-Idler Arm Nut ................................. 33 (44)
Relay Rod-To-Pitman Arm Nut ................................ 33 (44)
Side Cover Bolts
Montero .................................................. 36 (49)
Montero Sport ...................................... 41-47 (50-64)
Steering Gear Hose Fittings ................................ 11 (15)
Steering Gear-To-Frame Bolts ......................... 40-47 (54-64)
Tie Rod Adjusting Sleeve Lock Nuts ......................... 69 (93)
Tie Rod End Castle Nuts .................................... 33 (44)
Valve Housing Bolts
Montero .................................................. 36 (49)
Montero Sport ...................................... 41-47 (56-64)
Valve Housing Lock Nut ......................................... ( 1)
(1) - Tighten lock nut until it contacts bearing race.

[Pauly Faulkner]

3.0ltr wasn't dropped until the NL.
NK came with the 3ltr 12v SOHC option with the V5MT1 gearbox behind it

[Rallyant]

Gen 2

3.0V6 :-
same as Gen 1 except for NH & NJ auto has 7.25" diameter front diff (high pinion)

Is that a 28 spline, 29mm diameter or a 25 spline 29mm diameter?

[bakerboy]

Same as the V6 gen1 so that would be 28 spline

[Rallyant]

Thanks! my brain wasn't working to well before, I thought that would stop me using the 5.29 gears to suit one, BUT, ill be chucking in a locker with a 25 spline anyway as everything else is the same?

[Rallyant]

Do the gen2 ltr V6 auto have a 10 bolt front crown gear?

[bryce77]

Does anyone know if the late model triton diffs are the same as gen 3 paj
reason i ask is i wouldnt mind couple of eaton e lockers but they only build them for 2007 onwards triton

[nj swb]

Does anyone know if the late model triton diffs are the same as gen 3 paj
reason i ask is i wouldnt mind couple of eaton e lockers but they only build them for 2007 onwards triton

AFAIK, front diffs are the same, but rears are different (solid vs IRS). When ARB finally produced diff locks for 9.5" Pajero rears they introduced different models for Gen 2 / Gen 3. I would expect the Triton diff to be the same as the Gen 2 Paj rather than Gen 3.

Or I could be wrong.

[Rallyant]

A Gen1 2.5 LWB I just looked at had a 9" rear. Do all Diesels have a 9" and not an 8" as stated here? or just the 2.5?